An apparatus for manufacturing a thermoelectric module includes an alignment mechanism for aligning a plurality of thermoelectric elements with respect to a plurality of electrodes attached to a substrate, wherein the alignment mechanism includes a dispenser having a plurality of injection portions and the plurality of thermoelectric elements is inserted into the plurality of injection portions.
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1. An apparatus for manufacturing a thermoelectric module, comprising: an alignment mechanism for aligning a plurality of thermoelectric elements with respect to a plurality of electrodes attached to a substrate; and a bonding mechanism for bonding the plurality of aligned thermoelectric elements to the plurality of electrodes of the substrate, wherein the alignment mechanism includes a dispenser having a plurality of injection portions and the plurality of thermoelectric elements is inserted into the plurality of injection portions, the bonding mechanism having a heating cartridge for generating heat and a plurality of heat conducting portions extending from the heating cartridge, and each of the plurality of heat conducting portions is individually inserted into one of the plurality of injection portions.
An apparatus for manufacturing thermoelectric modules automatically aligns and bonds thermoelectric elements to electrodes on a substrate. The alignment mechanism uses a dispenser with multiple injection ports where thermoelectric elements are inserted. A bonding mechanism with a heating cartridge and heat conducting elements then individually inserts these conducting elements into the injection ports to bond the aligned thermoelectric elements to the substrate electrodes.
2. The apparatus according to claim 1 , wherein the plurality of injection portions have an inner diameter corresponding to a cross section of each of the thermoelectric elements and an inside of the injection portion is formed with a tapered surface.
The thermoelectric module manufacturing apparatus, as previously described, has injection ports within the dispenser that are precisely sized. The inner diameter of each port corresponds to the cross-section of the thermoelectric element it holds. The inside surface of each injection port is tapered to facilitate element insertion and alignment.
3. The apparatus according to claim 2 , wherein the plurality of thermoelectric elements includes a pair of thermoelectric elements having opposite polarities to each other and the pair of thermoelectric elements includes a first thermoelectric element and a second thermoelectric element having a width smaller than that of the first thermoelectric element.
In the thermoelectric module manufacturing apparatus, as previously described, the thermoelectric elements include pairs with opposite polarities. Each pair contains a first thermoelectric element and a second thermoelectric element, where the second element is designed to have a width smaller than the first element. This facilitates different electrical properties or connection configurations.
4. The apparatus according to claim 3 , wherein each of the plurality of injection portions has more than one first injection portion into which the first thermoelectric element is inserted and more than one second injection portion into which the second thermoelectric element is inserted.
In the thermoelectric module manufacturing apparatus, as previously described, the dispenser's injection ports are specifically configured to handle different sized thermoelectric elements. Each dispenser includes multiple "first injection ports" designed to accommodate the larger "first thermoelectric elements," and also includes multiple "second injection ports" designed to accommodate the smaller "second thermoelectric elements" for optimal arrangement and bonding.
5. The apparatus according to claim 1 , wherein the alignment mechanism further includes an oscillator connected to the dispenser to shake the dispenser.
The thermoelectric module manufacturing apparatus, as previously described, further improves the alignment process. An oscillator is connected to the dispenser, creating a shaking motion. This shaking helps the thermoelectric elements settle properly into the injection ports, ensuring accurate alignment before the bonding process.
6. The apparatus according to claim 1 , wherein the thermoelectric element has a body, a first end portion provided at one end of the body, and a second end portion provided at the other end of the body, and the first end portion or the second end portion has at least a partial non-flat surface.
The thermoelectric element used in the thermoelectric module manufacturing apparatus has a defined shape. It includes a main body, a first end, and a second end. Either the first end, the second end, or both are designed with a partially non-flat surface to enhance bonding or electrical contact with the electrodes on the substrate.
7. The apparatus according to claim 6 , wherein the body has a length longer than a width thereof.
The thermoelectric element, as previously described, is shaped with a longer body than its width. This specific aspect ratio of length to width in the thermoelectric element is a critical feature for its performance and manufacturability within the described apparatus.
8. The apparatus according to claim 6 , wherein at least one of the first end portion and the second end portion has a curved portion having a predetermined curvature radius.
The thermoelectric element, as previously described, is further refined in its design. At least one end (either the first or second end) features a curved section with a specified curvature radius. This curve is implemented to control the contact area or stress distribution when bonded to the substrate.
9. The apparatus according to claim 6 , wherein at least one of the first end portion and the second end portion has a conical surface or a pyramidal surface.
The thermoelectric element, as previously described, includes a special end shape. At least one of the element's ends (either the first or the second) is formed with either a conical or pyramidal surface. This provides a specific geometry for optimized bonding and electrical connectivity.
10. The apparatus according to claim 6 , wherein an edge of at least one of the first end portion and the second end portion is formed with a round portion.
The thermoelectric element, as previously described, features rounded edges. The edge of at least one end of the thermoelectric element (either the first or second end) includes a rounded section, mitigating sharp corners and potentially reducing stress concentration during the manufacturing and operation of the thermoelectric module.
11. The apparatus according to claim 6 , wherein the first end portion has a curved portion having a first curvature radius and the second end portion has a curved portion having a second curvature radius.
The thermoelectric element, as previously described, has distinct end shapes. The first end includes a curved section characterized by a "first curvature radius," while the second end also includes a curved section characterized by a "second curvature radius." This creates different contact characteristics at each end of the thermoelectric element.
12. The apparatus according to claim 11 , wherein the first curvature radius is equal to the second curvature radius.
The thermoelectric element, as previously described with different end curvatures, is designed with matching curvatures. The first curvature radius of the first end is equal to the second curvature radius of the second end, providing a symmetrical contact profile.
13. The apparatus according to claim 11 , wherein the first curvature radius is different from the second curvature radius.
The thermoelectric element, as previously described with different end curvatures, is designed with non-matching curvatures. The first curvature radius of the first end is different from the second curvature radius of the second end, creating a deliberate asymmetry in the contact profile.
Cooperative Patent Classification codes for this invention. Click any code to explore related patents in that topic.
June 16, 2016
August 15, 2017
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